If the problem happened within the bumper to bumper warranty and they attempted to fix it but its still not fixed and now out of warranty, then it will still be covered by the bumper to bumper...just because they cannot find the issue while its in warranty doesn't mean you have to take it in the rear after it falls out of warranty.
There are many things that can cause set a P0442...truthful, as some one that used to be a tech, they can straight up be a pain in the d1ck. I sure the guy working on it doesn't want it back for the same reason just as much as you don't want to take it back for the same effing problem.
Small evap leaks can be from something as simple as a little sand getting up into one of the vent tube connection joints to a bad tank pressure senor...or I have even heard about (from a co-worker) about an after market sound system installed and the installers used deck screws to hold the sub box down...the screws punctured the top of the fuel tank and would barely leak on a "smoke test" to the point where you could not see it.
It sounds like they need to drop everything out of the car and get a field engineer out there to inspect all the parts.
As for the lemon law route....its a PITA and with as many miles on it, its probably not worth it to be honest. They give you want the car is worth, not a new car.
If I was you I would call the Customer Assistance Center and gripe to them. They will get in contact with the dealer you the CAC will more than likely give you something to keep you happy. I have seen anything from a voucher for toward merchandise to them offering to pay for month of your car payment (that is usually when there is a major repair before the first maintenance interval though).
Last edited by S.Bretz; 05-30-2014 at 05:53 PM.